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E3T E3T E nergy E fficiency E merging T echnologies Microwave Assisted Thermal Sterilization - MATS™ Emerging Technologies Showcase January 21, 2015 Bill Wilson, P.E. Washington State University Extension Energy Program 1

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Introduction What we are going to discuss: New process technology for post-packaging processing (sterilization) of low-acid/high-moisture food products resulting in long-term, ambient condition, shelf-stable, food products preservation E3T E3T E nergy E fficiency E merging T echnologies 3

BPA TI Project Funding Acknowledgement http://www.bpa.gov/Doing%20Business/TechnologyInnovation/TIPProjectBriefs/2014-TIP-261.pdf E3T E3T E nergy E fficiency E merging T echnologies 4

Microwave Assisted Thermal Sterilization (MATS™) • Developed by Dr. Juming Tang’s Microwave Group at Washington State University, Pullman Campus – affiliated with the Department of Biological Systems Engineering • Adaptation of 915 MHz frequency microwave energy for internal heating of food products in their hermetically sealed storage containers to sterilization temperatures E3T E3T E nergy E fficiency E merging T echnologies

What is Post-Packaging Sterilization? • Process for deactivation of microorganisms and their spores. Internal temperatures in excess of 212 o F required (generally 250 – 265 o F), with adequate “holding” time once temperature is reached • We are all very familiar with conventional post –packaged sterilization technologies as food processors, domestic food preservationists, or consumers • Examples of products created using conventional technologies and target categories for MATS™ technology follow …. E3T E3T E3T E3T E nergy E nergy E fficiency E fficiency E merging T echnologies E merging T echnologies 6

Examples of Post-Packaged Sterilized Products E3T E3T E nergy E fficiency E merging T echnologies

How is Post Packaging Thermal Sterilization Achieved ? • Imparting thermal energy to heat container and contents to sterilization temperature • For flexible or semi-rigid non-metallic containers in particular must be done in pressurized atmosphere environment to avoid product water content vaporization • Most frequently, pressurized atmosphere is steam (15 psig sat. steam ~247 o F), or hot water at sterilization temperature maintained at 20 psig or greater pressure E3T E3T E nergy E fficiency E merging T echnologies

Attributes of MATS™ vs. Conventional Technologies • Benefits  Significant reduction in thermal processing time (1/4 to 1/10 of conventional processing time)  Greatly improved product visual and sensory appeal - particularly prepared meals containing delicate ingredients  Improved nutrient retention  Inherently capable of adaptation to continuous-type sequential processing system design  Shelf-stable end-products eliminate refrigeration requirements for processing, warehousing, transportation, retail sales storage/presentation  Initial indication of a reduction in processing energy intensity (gross combined process energy consumption/unit mass of product) – usually stated as Btu’s per lb. of product • Drawbacks  Processing energy cost/production unit increase due to electrical vs. thermal energy utilization (particularly for natural gas) E3T E3T E nergy E fficiency E merging T echnologies

Conventional Sterilization Methods • Conventional Technologies  Steam heated retorts (also called “autoclaves”)  Water immersion retorts  Steam water spray retorts • All types –  Batch operation (most typical)  Continuous operation (rare) E3T E3T E nergy E fficiency E merging T echnologies

Batch-Type Retorts – “Still” Steam Disadvantages  Warm-up losses  Vent & bleeder losses  Product thermal mass  Long come-up & cook time  Long product cooling time

Batch-Type Retorts – Water Immersion (with Water Recovery Vessel) Disadvantages  Warm-up losses  Long come-up & cook time  Long product cooling time E3T E3T E nergy E fficiency E merging T echnologies

Batch-Type Retorts – (Steam Water Spray) Advantages Disadvantages  No Steam Venting Loss  Warm-up losses  No Continuous Bleeder Loss  Electrical & Compressed  Minimal Water Volume Heat-up Air Consumption E3T E3T E nergy E fficiency E merging T echnologies

WSU MATS™ 40 kW Pilot Line

WSU MATS™ Semi-Continuous 40 kW Pilot Line View: Preheating Section (lower) Microwave 20 KW 915 MHz Microwave Section (Upper) Generators E3T E3T E nergy E fficiency E merging T echnologies

Summary of WSU MATS™ Major Milestones July 2001 Formed WSU Microwave Consortium I Developed first 915 MHz single mode pilot system (10 kW) July 2001 Received US patent for 915 MHz single mode microwave Oct. 2006 sterilization system design Developed a second generation system semi-continuous Aug. 2007 system (40 kW) Received FDA acceptance for MW sterilization of mashed Oct. 2009 potato in 10 oz. trays Nov. 2010 Formed MW Consortium II, focusing on commercialization Food Chain Safety (Maple, Valley, WA) is granted license for exclusive rights for commercialization of MATS™ Nov. 2010 Technology [Now 915 Labs] Received FDA acceptance for MW Dec. 2010 sterilization of salmon fillets in sauce in 8 oz. pouches Mar. 2012 Received non-objection letters from USDA FSIS

Retort Processes Energy Consumption Comparisons • Like many Energy Consumption Energy Comparisons – “It Depends” Intensity??  Currently batch or continuous operation?  Product temperature increase required  Equipment capacity utilization and density of product pack  Initial projection of Microwave compared with batch processing indicates favorable energy intensity and overall energy efficiency metrics E3T E3T E nergy E fficiency E merging T echnologies

Commercial Assessment Outcome Summary Energy Intensity (As Measured/Estimated) Energy Intensity Energy Intensity, Btu/lb Product 1,293 1,400 1,200 1,000 864 800 600 300 400 260 200 0 Still Steam Immersion w/ Steam Water Continuous Water Recovery Spray Rotary Retort (cans) Lb. Product/Ft 3 Usable Retort Volume (As Measured/Estimated) Product/Volume Ratio 32.5 35 30 25 Lb/Ft 3 20 15 10.4 7.1 10 5 0 Still Steam Immersion w/ Water Steam Water Spray Recovery

Commercial Assessment Outcome Summary Energy Intensity Normalized for Pack Density & Temp. Rise Energy Intensity Energy Intensity, Btu/lb Product 1293 1,400 1,200 1,000 800 658 651 600 400 260 200 0 Still Steam Immersion w/ Steam Water Continuous Water Recovery Spray Rotary Retort (cans) E3T E3T E nergy E fficiency E merging T echnologies

Input Energy Distribution Input Energy Distribution (As Measured/Estimated ) 100% Electrical 90% 29.0% 18% Product & Container 80% Sensible Heat: 70% Surface Losses 56.2% 60% 79.2% Preheating 50% Bleeder Losses 40% 30% Vent Losses 20% 10% 0% Still Steam Water Steam Water Continuous Horizontal Immersion Spray Rotary Retort (cans) E3T E3T E nergy E fficiency E merging T echnologies

For Additional Information: WSU Microwave Group: www.microwaveheating.wsu.edu Food Chain Safety/915 Labs : www.fcsmats.com Bill Wilson: wilsonb@energy.wsu.edu (360) 956-2041 E3T E3T E3T E3T E nergy E nergy E fficiency E fficiency E merging T echnologies E merging T echnologies 21

Thank you for attending Information and registration at www.e3tnw.org/webinars Join our email list for notification of future webinars at subscribe-e3tnw@listserv.energy.wsu.edu More information about emerging technologies : E3T database: www.e3tnw.org E3T Program: www.bpa.gov/energy/n/emerging_technology/ Conduit: www.ConduitNW.org Thank you for attending our E3T Showcase Webinar! E3T E3T E nergy E fficiency E merging T echnologies 22